Denyo DCA-150ESK Instruction Manual Download Page 67

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9— 6 Table of periodical maintenance and checking

0:C h eck or Clean 0:Replacement ☆:Only first time

List of maintenance

and inspection

daily

first

50h

every

250h

every

500h

every

lOOOh

Checking on oil level and stain of oil

Checking on cooling water

Checking on fan belt

Checking on fuel and drain

Checking on battery acid level

Checking on for water and oil leakage

Checking on bolts and nuts for looseness

Checking on exhaust color, sound and vibration

Engine

Checking on meters and warning lamps

Replacement of engine oil

☆ о

Replacement of engine oil filter element

☆ о

Clean air cleaner element

Checking on specific gravity of battery

Cleaning radiator

Replacement of fuel filter

Cleaning fuel tank

Replacement of air cleaner element

SS Inspection of engine valve clearance

☆ о

is Adjust fuel injection nozzle

$ Inspection of timing of fuel injection

Checking on rubber suspension

Checking on nylon and rubber hose

Checking on lining

Checking on generator case grounding

Generator

Checking on insulation resistance

Checking on terminal and connected section

Ж Contact distributor or our office.

☆ This symbol represent first time of inspection, next time is ordinary schedule.

Inspection time is different by the engine,in detail, please refer "Engine Instruction

Manual" furnished separately.

- 66 -

Summary of Contents for DCA-150ESK

Page 1: ...73 343 384 55 89 4932 77 34 06 3412 26 03 58 395 279 98 46 996 312 96 26 47 843 206 01 48 4012 72 03 81 4842 92 23 67 3842 65 04 62 8332 68 02 04 861 203 40 90 391 204 63 61 4712 77 13 04 4742 52 20...

Page 2: ...duct or property damage Note This symbols show handling precautions for effective operation and many years of satisfactory operation Some of the items shown by f CAUTION may also cause death or seriou...

Page 3: ...stributor or our office specifying the nameplate No shown below and ask for new ones No Parts name Parts number No Parts name Parts number 1 Safety instruction B9211 0140 5 Warning Hot surfaces B9052...

Page 4: ...r in a place where exhaust gases stays Do not use the machine indoors or in storehouse tunnel ship hold tank etc of poor ventilation If it becomes necessary to use the machine in the above places the...

Page 5: ...l cover closed and the terminal bolts tightened while the machine is running A low voltage is generated even when the machine is in low speed idle operation Be sure to stop the machine completely Do n...

Page 6: ...njury Rotary unit which runs at a high speed is located in the machine Note that it is very dangerous if you touch it Be sure to close the door and lock it during operation When the door needs to be o...

Page 7: ...chips etc and hazardous objects oil powder etc near the machine Wipe off spilt fuel and oil WARNING HOT COOLANT can cause severe scalds I If the radiator cap is opened while the water temperature is h...

Page 8: ...ng square timbers as shown right put each machine making sure that the weight is even Do not operate the machines in the state of stacking to prevent falling or dropping accidents A CAUTION F f 5 R V...

Page 9: ...d from the battery may be ignited and exploded by sparks For maintenance of the machine disconnect the ground cable on the ground side I The battery acid is dilute sulfuric acid Improper handling will...

Page 10: ...by projections which may cause injuries A CAUTION Noise This machine generates large noise if the door is open Surrounding to large noise may cause hearing trouble Close and lock the door during opera...

Page 11: ...alling accident When lifting the machine use the hanger located at the roof center Keep out under the lifted machine I Do not lift or do not transport the machine during operation as it may cause dama...

Page 12: ...on 2 1 Outline and part names 1 output terminal 2 control panel 3 operating panel 4 engine indicator 5 fuel in 6 hanger rod 7 support hook 8 coolant in 9 fuel drain plug 10 oil drain plug 11 exhaust g...

Page 13: ...1 control box 2 diesel engine 3 battery 4 radiator 5 reserve tank 6 fuel filter 7 oil filter 8 AC generator 9 air cleaner 10 dipstic 11 engine oil in 1 2...

Page 14: ...lg in e speed o i l press it egr a t i ng t ime b a t t e r y l a r gi n g v o l t a g e wat er mp m n Lamps I T Duel 3 AC VOLTMETER INCLUDE VOLTMETER CHANGE OVER SWITCH I t e A1 k P I L O T LAMP 5 C...

Page 15: ...g voltage or engine coolant temperature Each indication is selectable by pushing the SELECT button Unit Indicated Items min engine speed X engine oil pressure hour run hours V battery charging voltage...

Page 16: ...gine Coolant Temperature That should indicate a temperature between 75 to 90 C at engine running Note If that would indicate higher temperature disconnect all loads decrease the speed for cool down op...

Page 17: ...on changes to AUTO and the abnormal value and unit will be indicated lighting on and off 2 When the abnormal condition is corrected the on and off indication will stop 3 If engine would stop urgently...

Page 18: ...of them Ammeter change over switch When running either the three phase or single phase load this meter indicates the current flowing into the load The current of each phase can be checked using the a...

Page 19: ...gine control unit will sometimes cause a temporal indication of the light when operating the starter switch but it is not related to any of the warming 2 Oil pressure failure OIL PRESS OIL PRESS If th...

Page 20: ...s the position to start the engine When your hand is released from the key after starting it is automatically set in the position of RUN Preheat This is the position to start the engine when the air t...

Page 21: ...aker to turn ON OFF the load to prevent damage to the circuit breaker When it trips with overcurrent the handle of the breaker stops between ON and OFF positions This is what is called the trip condit...

Page 22: ...the regulator to clockwise to increase the voltage and counter clockwise to decrease it Adjust the voltage to the rated voltage with this regulator 2 Overcurrent relay This relay is used to trip the...

Page 23: ...ling accident When lifting the machine use the hanger located at the roof center Keep out under the lifted machine Do not lift or do not transport the machine during operation as it may cause damage t...

Page 24: ...ine running generates vibration during operation of the machine When installing the machine be sure to observe the following points Install the machine horizontally on a solid foundation Operation on...

Page 25: ...ir from the radiator and exhaust gases to be discharged and to supply water to the radiator When the machine is operated in a place with much dust or salt careful maintenance is required to prevent cl...

Page 26: ...d tri_U2 a zd 2 ffi w CCX 400 440V 380V 415V 480V 200 220V 190V 240V Method For Selecting Output Voltage The output voltage of 200 220V or 400 440V can be selected with the voltage change over plates...

Page 27: ...the load drops which lowers the working efficiency or causes failure in operation Select the length and size of cable so that the voltage drop e obtained by the following equation is within 5 of the r...

Page 28: ...re operating the machine Do not use damaged cables to prevent electric shock Insufficient tightening of bolts will generate heat at connections which may result in fire accidents When connecting make...

Page 29: ...rminal Connect the load to the output terminal after confirmation of load phase and voltage Use U V Wfor three phase load 200 220V or 400 440V 190V 380V 415V 240V 480V u V w O V w 9 9 U V w Use 0 U 0...

Page 30: ...of the machine for turning the load ON and OFF may result in breaker failure In connecting the load be sure to stop the engine and turn OFF the breakers on the control panel Don t contact the connecti...

Page 31: ...ith an earth leakage relay to detect any leakage produced due to such trouble as insulation failure of the load during operation and to cut off the circuit for protection against any accident such as...

Page 32: ...that using attached grounding rod But if grounding resistance is over 100 Q provide the grounding rod which surface area contacted the ground is large Grounding of the case grounding of the machine Us...

Page 33: ...rrent Precaution in grounding Select a shady and highly moist place and burry the grounding rod in such way that its top end is completely hidden in the ground If burying the grounding rod on the plac...

Page 34: ...on and the breakers to be activated the leakage relay can be regarded as operating normally 5 Press the RESET button and return the breaker to the OFF position This allows the breaker to be turned to...

Page 35: ...ltage parts Before operating close the door and lock the side door for safe operation and for prevention of noise Note If the warning lamp lights stop the engine and check the cause of it Note Check f...

Page 36: ...Removal of foreign objects in machine Inspection 1 Checking on engine oil Read the instruction manual for the engine furnished separately Checking the level of engine oil by the dipstick Make sure the...

Page 37: ...ling water in the reserve tank is within the range of FULL LOW When it is below the low limit supply additional water immediately Normally only the water level of the reserve tank needs to be checked...

Page 38: ...s about 6kg the position shown by arrow mark middle of belt with your thumb The bend should be within the range of 10 15mm Parts number of fan b elt Parts number manufacture Parts number of manufactur...

Page 39: ...your clothes or skin wash it out with a large volume of water immediately If it gets in your eyes wash with a large volume of water immediately and consult your doctor In the worst case it will put o...

Page 40: ...eck for loose parts Check for loose bolts and nuts Loose parts should be tightened firmly Particularly make check on the fitting of air cleaner muffler turbo charger etc disconnection of electric wiri...

Page 41: ...hen engine is already warm starter switch PREHEAT preheat lamp red heated starter switch START Y starter switch RUN engine startup When it is cold Y 4 warm up operation about 5 minutes warm up operati...

Page 42: ...the throttle handle toward the HIGH SPEED clock wise two or three times 3 Set the starter in Preheat position This switch must be ON until the preheat lamp becomes red heated Turn the starter switch t...

Page 43: ...52 5Hz 1575mm1 60Hz drive 62 5Hz 1875mm1 If the idling speed set above speed frequency becomes nearly 50Hz or 60Hz in the rated load 6 Set the voltage to the rated by the voltage regulator and turn t...

Page 44: ...blue Normal Black Abnormal incomplete combustion White Abnormal combustion of oil due to failure of oil 2 Adjustment during operation Set the tachometer and frequency meter to the rated by the thrott...

Page 45: ...nge of 750 to 900mm 1 and drive the engine for approximately five minutes 4 Check the panel light goes out 5 Set the starter switch in STOP position The engine will stop immediately 6 Remove the key f...

Page 46: ...49kPa high jacket water temperature WATER TEMP set point 97 C Stop set point lOl C Battery charging failure stop 26 OV overcurrent of generator When overcurrent flows the device acts earth leakage Whe...

Page 47: ...ncies engine governor characteristics etc For this reason it is requested for easy paralleling to select the quite same type of the generating sets for manufacturer model etc Study this manual careful...

Page 48: ...he sequences are in the different direction In case the two lamps turn on and off alternately recheck the cable connections for correct phase sequence 6 At the instance when the synchronizing lamps tu...

Page 49: ...ammeters show an imbalance in loading make it in equal loading by adjusting the throttle lever for engine rpm The set is to undertake more load sharing when the engine rpm is adjusted higher while les...

Page 50: ...ted lower 2 Keep the single parallel change over switch in the positiori PARALLEL Note If it is turned to SINGLE a cross current occurs between the alternators and trips the circuit breakers due to ov...

Page 51: ...Turn off the breakers on the load side 2 Turn off the main circuit breaker on each generating set 3 Shut down each engine referring to 5 4 Shut downj C IR C U ITB R E A K E R DFFl g o t I CIRCUIT BRE...

Page 52: ...ty Recommended oil viscosity is SAE 10W 30 all season type Use oil according to ambient temperature referring to the table below Ambient temperature t 3 0 2 0 1 0 0 10 20 30 4 S A E 2 0 4 S A E 3 0 4...

Page 53: ...following percentages are recommended for each ambient temperature 30 l o t 40 2 0 1 50 3 0 C In case of replenishment use LLC of the same brand and the same density Normally LLC should be replaced e...

Page 54: ...gases generated from the battery may be ignited and exploded by sparks For maintenance of the machine disconnect the cable on the ground side The battery acid is dilute sulfuric acid Improper handlin...

Page 55: ...d cable last While the battery is being charged open all the liquid plugs to discharge thegas Keep the battery away from fire to prevent unexpected explosion Handle the battery carefully to prevent el...

Page 56: ...clip of the booster cable B connected to the engine block of the machine in trouble D Remove the clip of the booster cable B connected to the t e r m i n a l of normal machine Remove the clip of the...

Page 57: ...ich moving parts at a high speed is located in the machine Care should be taken during operation When the machine needs checking or maintenance be sure to stop it in advance A WARNING ELECTRIC SHOCK c...

Page 58: ...ction or maintenance be sure to stop it in advance Even after the machine stops the inside of the bonnet is still hot Wait until the engine is cooled sufficiently A CAUTION BATTERY Battery generates f...

Page 59: ...d protectors Do not put on baggy clothes necklace etc because they are easily caught by projections which may cause injuries CAUTION Handling of waste liquid Waste liquid from the machine should be re...

Page 60: ...fuel filter cartridge Cleaning of radiator and intercooler Checking for terminal and connection of the circuit Checking every 250 hours is also required 1000 hours Checking every 1000 hours Cleaning i...

Page 61: ...filter element Replace the engine oil filter at 50 hours only first time and every 250 hours after second time Cartridge type Cartridge type is unit of filter case and element Remove the cartridge typ...

Page 62: ...nt This element should be cleaned regardless of operating time when the warning lamp of Air filter blinding goes on Dry dust clings on element Remove the air cleaner element and dean the element with...

Page 63: ...cable from the output terminal as shown at below Turn ON the circuit breaker and measure the insulation resistance between the output terminal bolt and the bonnet If the measured resistance is less th...

Page 64: ...id The relation between battery charge condition charging rate and specific gravity is as shown below Liquid Charging temp rate C 2 0 0 1 0 1 0 0 1 28 1 29 1 30 9 0 1 26 1 27 1 28 8 0 1 24 1 25 1 26 7...

Page 65: ...el piping For details refer to the instruction manual for the engine A nameplate showing the method of discharging air is also attached to the machine Parts number of fuel filter cartridge Parts numbe...

Page 66: ...3 KOMATSU 600 181 6820 3 Checking on rubber suspension Check on the rubber suspension whether it is damaged or deformed by the oil Contact distributor or our office to replace the rubber suspension if...

Page 67: ...engine oil filter element Clean air cleaner element Checking on specific gravity of battery Cleaning radiator Replacement of fuel filter Cleaning fuel tank Replacement of air cleaner element S SInspec...

Page 68: ...the machine Care should be taken during operation When the machine needs checking or maintenance be sure to stop it in advance A WARNING ELECTRIC SHOCK can kill High voltage units are located in the m...

Page 69: ...ection or maintenance be sure to stop it in advance Even after the machine stops the inside of the bonnet is still hot Wait until the engine is cooled sufficiently A CAUTION BATTERY Battery generates...

Page 70: ...element Repair engine Replace element Engine stop by oil failure Oil shortage Oil pressure switch failure Blinded oil filter Supply Replace Replace element Over heat water temperature Cooling water sh...

Page 71: ...ltmeter failure Replace AVR failure Contact distributor or our office VR failure Burned rotary rectifier Contact Applied load causes load AVR failure distributor or voltage drop Burned main field exci...

Page 72: ...fer to the instruction manual for the engine provided separately A CAUTION Stacking Improper stacking of machines may cause falling or dropping accidents When stacking other machines on this machine b...

Page 73: ...F CYLINDERS 6 C I N E BORE x STROKE 102 X 120 mm TOTAL DISPLACEMENT 5 88 L RATED OUTPUT 1500 1800mm _1 113 135 kW BATTERY DOMESTIC STANDARD 95E41R X 2 FUEL DIESEL FUEL ASTM No 2 or equivalent FUEL TAN...

Page 74: ...5 135 150 150 150 kW 100 100 90 108 120 120 120 rated voltage V 190 380 200 400 220 440 190 380 200 400 220 440 240 480 rated current A 380 190 361 180 295 148 410 205 433 217 394 197 361 180 auxiliar...

Page 75: ...H EA TED A I R AND 12 3 Outline drawing...

Page 76: ...12 4 Generator connection diagram 75...

Page 77: ...ENGINE INDICATOR 1 m a t 1 1 ctCtT T Mt 1 2 5 Engine wiring diagram A E i S 2 Umiig 76...

Page 78: ...tank and pipe it as illustrated in Fig 2 then turn the change over valve in the arrow indicated direction before operating the machine If the outside machine tank is not used with the piping removed...

Page 79: ...03 81 4842 92 23 67 3842 65 04 62 8332 68 02 04 861 203 40 90 391 204 63 61 4712 77 13 04 4742 52 20 81 3519 55 03 13 495 268 04 70 8152 59 64 93 8552 20 53 41 831 429 08 12 772 734 952 31 3843 20 46...

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Denyo DCA-150ESK, Instruction Manual

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